High-performance optical absorber comprising functionalized, non-woven, cnt sheet and texturized polymer film or texturized polymer coating and manufacturing method thereof

ABSTRACT

A method using capillary force lamination (CFL) for manufacturing a high-performance optical absorber, includes: texturizing a base layer of the high-performance optical absorber, the base layer comprising one or more of a polymer film and a polymer coating; joining a surface layer of the high-performance optical absorber to the base layer, the surface layer comprising a non-woven carbon nanotube (CNT) sheet; wetting the joined surface layer and base layer with a solvent; allowing surface tension forces of the solvent to draw the non-woven CNT sheet into the base layer, thereby texturizing the surface layer; drying the joined surface layer and base layer; and treating the resulting base layer with plasma, creating the high-performance optical absorber.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a divisional application of U.S. patentapplication Ser. No. 18/125,204, filed Mar. 23, 2023, entitled“HIGH-PERFORMANCE OPTICAL ABSORBER COMPRISING FUNCTIONALIZED, NON-WOVEN,CNT SHEET AND TEXTURIZED POLYMER FILM OR TEXTURIZED POLYMER COATING ANDMANUFACTURING METHOD THEREOF,” which is a divisional application of U.S.patent application Ser. No. 17/947,375, filed Sep. 19, 2022 (now U.S.Pat. No. 11,650,356, issued May 16, 2023), entitled “HIGH-PERFORMANCEOPTICAL ABSORBER COMPRISING FUNCTIONALIZED, NON-WOVEN, CNT SHEET ANDTEXTURIZED POLYMER FILM OR TEXTURIZED POLYMER COATING AND MANUFACTURINGMETHOD THEREOF,” which is a continuation application of U.S. patentapplication Ser. No. 17/583,446, filed Jan. 25, 2022 (now U.S. Pat. No.11,555,949 issued Jan. 17, 2023), entitled “HIGH-PERFORMANCE OPTICALABSORBER COMPRISING FUNCTIONALIZED, NON-WOVEN, CNT SHEET AND TEXTURIZEDPOLYMER FILM OR TEXTURIZED POLYMER COATING AND MANUFACTURING METHODTHEREOF,” which is a continuation application of U.S. patent applicationSer. No. 17/412,381, filed Aug. 26, 2021 (now U.S. Pat. No. 11,307,331issued Apr. 19, 2022), entitled “HIGH-PERFORMANCE OPTICAL ABSORBERCOMPRISING FUNCTIONALIZED, NON-WOVEN, CNT SHEET AND TEXTURIZED POLYMERFILM OR TEXTURIZED POLYMER COATING AND MANUFACTURING METHOD THEREOF,”which is a continuation application of U.S. patent application Ser. No.17/136,703, filed Dec. 29, 2020 (now U.S. Pat. No. 11,175,437, issuedNov. 16, 2021), entitled “HIGH-PERFORMANCE OPTICAL ABSORBER COMPRISINGFUNCTIONALIZED, NON-WOVEN, CNT SHEET AND TEXTURIZED POLYMER FILM ORTEXTURIZED POLYMER COATING AND MANUFACTURING METHOD THEREOF”, the entirecontents of which are incorporated herein by reference.

STATEMENT OF GOVERNMENT RIGHTS

The Government of the United States of America has rights in thisinvention pursuant to Government Contract No. 11-C-0042.

SUMMARY

A high-performance optical absorber includes: a texturized base layer,the base layer comprising one or more of a polymer film and a polymercoating; and a surface layer located above and immediately adjacent tothe base layer, the surface layer joined to the base layer, the surfacelayer comprising a plasma-functionalized, non-woven carbon nanotube(CNT) sheet.

A method using capillary force lamination (CFL) for manufacturing ahigh-performance optical absorber includes: texturizing a base layer ofthe high-performance optical absorber, the base layer comprising one ormore of a polymer film and a polymer coating; joining a surface layer ofthe high-performance optical absorber to the base layer, the surfacelayer comprising a non-woven carbon nanotube (CNT) sheet; wetting thejoined surface layer and base layer with a solvent; allowing surfacetension forces of the solvent to draw the non-woven CNT sheet into thebase layer, thereby texturizing the surface layer, thereby texturizingthe surface layer; drying the joined surface layer and base layer; andtreating the resulting base layer with plasma, creating thehigh-performance optical absorber.

DESCRIPTION OF THE DRAWINGS

The accompanying drawings provide visual representations which will beused to more fully describe various representative embodiments and canbe used by those skilled in the art to better understand therepresentative embodiments disclosed herein and their inherentadvantages. In these drawings, like reference numerals identifycorresponding elements.

FIG. 1 is a drawing of a high-performance optical absorber comprising atexturized base layer, the base layer comprising one or more of apolymer film and a polymer coating, the optical absorber furthercomprising a surface layer located above and immediately adjacent to thebase layer, the surface layer comprising a plasma-functionalized,non-woven CNT sheet.

FIGS. 2A-2F are a set of six drawings depicting a method formanufacturing a high-performance optical absorber using capillary forcelamination (CFL).

FIGS. 3A-3D are a set of four drawings depicting four differentgeometries usable in a high-performance optical absorber comprising atexturized base layer, the base layer comprising one or more of apolymer film and a polymer coating, the optical absorber furthercomprising a surface layer located above and immediately adjacent to thebase layer, the surface layer comprising a plasma-functionalized,non-woven CNT sheet.

FIG. 4 is a graph of modeling data depicting superior reflectanceperformance relative to the prior art of a high-performance opticalabsorber comprising a non-texturized base layer, the base layercomprising one or more of a polymer film and a polymer coating; and asurface layer located above and immediately adjacent to the base layer,the surface layer comprising a plasma-functionalized, non-woven CNTsheet.

FIG. 5 is a flow chart of a method for manufacturing a high-performanceoptical absorber.

FIG. 6 is a flow chart of a method for manufacturing a high-performanceoptical absorber.

DETAILED DESCRIPTION

Embodiments of the invention provide a practical method for producinghigher performance optical absorbers comprising a texturized base layer,the base layer comprising one or more of a polymer film and a polymercoating, the optical absorber further comprising a surface layer locatedabove and immediately adjacent to the base layer, the surface layercomprising a plasma-functionalized, non-woven CNT sheet, for use inaerospace instruments as well as for solar energy conversionapplications. Embodiments of the invention enhance optical absorbanceproperties of non-woven carbon nanotube (CNT) materials through creationat a surface of an absorber of one or more of a functionalized layer anda texturized layer. For example, the CNT materials comprise one or moreof a non-woven CNT sheet and a CNT film. For example, the plasmacomprises oxygen plasma. Plasma functionalization creates an oxygenateddielectric layer on top of the non-woven CNT sheet that is one or moreof less refractive and less reflective than the non-woven CNT sheet.

For example, the non-woven CNT sheet comprises one or more ofhorizontal, randomly-oriented CNT and horizontal, randomly orientedmulti-walled CNT (MWCNT) having a porosity between approximately 40% andapproximately 90%. Preferably, the one or more of horizontal,randomly-oriented CNT and horizontal, randomly oriented MWCNT has aporosity between approximately 65% and approximately 75%. For example,the one or more of horizontal, randomly-oriented CNT and horizontal,randomly oriented MWCNT has an areal density between approximately 10grams per square meter (g/m²) and approximately 30 g/m². Preferably, theone or more of horizontal, randomly-oriented CNT and horizontal,randomly oriented MWCNT has an areal density between approximately 12g/m² and approximately 15 g/m². For example, the CNT sheet is Miralon,manufactured by Nanocomp Technologies, Inc. (www.miralon.com) ofMerrimack, New Hampshire.

Texturization of the base layer comprising one or more of a polymer filmand a polymer coating introduces a geometric light-trapping structure tothe absorber. The combined surface functionalization and texturizationtreatment creates an optical absorber having a dielectric/conductorstructure whose design may be tailored depending on details of thetexturization. Texturization of the non-woven CNT sheet is optional butit does enhance the performance of the optical absorber.

FIG. 1 is a drawing of a high-performance optical absorber 100comprising a base layer 110, the base layer 110 comprising one or moreof a polymer film (not explicitly shown) and a polymer coating (notexplicitly shown).

The optical absorber 100 further comprises a surface layer 120, thesurface layer 120 comprising a non-woven CNT sheet 120 that isplasma-functionalized. The surface layer 120 comprises multi-walled CNTs(MWCNTs) as suggested by a blown up view 125 of a 1 micron cross-sectionof the surface layer 120. The surface layer 120 comprises anon-functionalized surface sub-layer 127 and also comprises afunctionalized surface sub-layer 128. The plasma-functionalized surfacesub-layer 128 absorbs a substantial portion of the incident light 115and reflects a small portion of the incident light 115 via Lambertianreflectance 117, meaning substantially angle-independent uniformreflectance of the incident light 115.

As depicted, the base layer 110 comprises rectangular-groovetexturization. As depicted, the base layer 110 comprises rectangularridges 130A-130D. Successive rectangular ridges 130A-130D are separatedfrom each other by a distance defined as a pitch p 133. Each successivepair of the rectangular ridges 130A-130D form between them a rectangulargroove 135A-135C. Rectangular grooves 135A-135C have respective groovewidths 137A-137C. The rectangular grooves 135A-135C create respectivefloors 136A-136C. The rectangular grooves 135A-135C also createrespective groove walls 137A-137F. The rectangular ridges 130A-130D eachhas a respective ridge width 140A-140D approximately equal to therespective groove widths 138A-138C. Accordingly, a top surface area 142is approximately equal to a floor surface area 144. Therefore the topsurface area 142 is approximately equal to half of the top surface areaof non-texturized prior art having a similar shape, and therefore thereflectance of the high-performance optical absorber 100 should bereduced to approximately 50% of non-texturized prior art having asimilar shape. Exact details of the amount by which reflectance isreduced will depend on an amount of light absorbance by one or more ofthe groove walls and the floor.

The non-functionalized surface sub-layer 127 has a thickness t 150.

The ridges 130A-130D each has a height h 160 above the surface layer120. Preferably, although not necessarily, the pitch p 133 is greaterthan or equal to 10×λ, where λ is the wavelength of the incident light.Preferably, although not necessarily, the thickness t 150 is greaterthan or equal to 10×λ, where λ is the wavelength of the incident light.Preferably, although not necessarily, the height h 160 is greater thanor equal to 10×λ, where λ is the wavelength of the incident light.

An exemplary index of refractionn_(non-functionalized surface sub-layer) of the non-functionalizedsurface sub-layer 127 is approximately 2.5. An exemplary index ofrefraction n_(functionalized surface sub-layer) of the functionalizedsurface sub-layer 128 is between approximately 1.2 and approximately1.6.

FIGS. 2A-2F are a set of six drawings depicting a method formanufacturing a high-performance optical absorber using capillary forcelamination (CFL).

FIGS. 2A-2B are a set of two drawings depicting two different methods toperform the first step in the method for manufacturing thehigh-performance optical absorber.

FIG. 2A is a drawing depicting a first method using an embosser 205 toperform the first step in the method for manufacturing thehigh-performance optical absorber (not shown in this figure). Theembosser 205 comprises an embossing pattern roll 210 configured togenerate a micro-macro feature 215 in the base layer 110. The base layer110 comprises one or more of a polymer film (not explicitly shown inthis figure) and a polymer coating (not explicitly shown in thisfigure). Alternatively, or additionally, the embosser is also configuredto generate a micro-macro feature 215 in the surface layer (not shown inthis figure). As depicted, the pattern roll 210 generates a triangularmicro/macro feature 215 in the base layer 110. For example, the embosser205 comprises one or more of a thermal embosser 205 and a mechanicalembosser 205.

The illustrated first method uses the embosser 200 for texturizing thebase layer 110. As mentioned above, alternatively, or additionally, theembosser 205 can also simultaneously texturize the surface layer (notshown in this figure).

FIG. 2B is a drawing depicting a second method using an engraver 220 toperform the first step in the method for manufacturing thehigh-performance optical absorber (not shown in this figure). Theengraver 220 texturizes the base layer 110.

For example, the engraver 220 comprises a laser engraver 220. Forexample, the laser engraver 220 comprises one or more of a rasterengraver 220 and a vector engraver 220.

Alternatively, or additionally, the same basic procedure outlined inthis figure can instead be performed using a three-dimensional (3D)printer 220 instead of an engraver 220.

In FIG. 2C, the high-performance optical absorber 100 is created byjoining the surface layer 120 comprising the CNT sheet to the base layer110. For example, and as depicted, the surface layer 120 is laid on topof the base layer 110, creating the optical absorber 100.

In FIG. 2D, the optical absorber 100 comprising the base layer 110 andthe CNT sheet layer 120 is wetted with a solvent 230. For example, thesolvent 230 is wicked into the non-woven CNT sheet 120. For example, thesolvent 230 has a high surface tension. For example, the solvent 230comprises one or more of acetone, water, methanol, ethanol, isopropyl,and another solvent.

In FIG. 2E, the optical absorber 100 is dried. For example, and asdepicted, a dryer 240 dries the optical absorber 100. As the surfacelayer 120 dries, one or more of surface tension and capillary action ofthe solvent (not shown in this figure) during the drying process helpsdo one or more of collapse the surface layer 120, condense the surfacelayer 120, and draw the surface layer 120 onto the base layer 110. Whendried, the surface layer 120 forms a conformal layer 120 on a surface ofthe base layer 110.

In FIG. 2F, the surface layer 120 is plasma-treated using plasma 250.For example, the surface layer 120 is plasma-treated using oxygen plasma250. Plasma functionalization may be performed one or more of prior toand subsequent to texturization of the polymer film. The plasmafunctionalization may be performed one or more of prior to andsubsequent to wetting with the solvent of the surface layer 120comprising the non-woven CNT sheet, creating the high-performanceoptical absorber 100.

FIGS. 3A-3D are a set of four drawings depicting four differentgeometries usable in a high-performance optical absorber comprising atexturized base layer, the base layer comprising one or more of apolymer film and a polymer coating, the optical absorber furthercomprising a surface layer located above and immediately adjacent to thebase layer, the surface layer comprising a plasma-functionalized,non-woven carbon nanotube (CNT) sheet.

As shown in FIGS. 3A-3D, various texturization geometries are possible,some of which may provide even lower reflectance than the rectangulartexturization depicted in FIGS. 1 and 2A-2E.

Depicted in FIG. 3A are the sheet absorber 100A having a rectangulargeometry, the sheet absorber 100A comprising the base layer 110 and thesurface layer 120, the base layer 110 comprising one or more of apolymer film 110 and a polymer coating 110, the surface layer 120comprising a non-woven carbon nanotube (CNT) sheet 120. The base layer110 comprises rectangular-groove texturization. As depicted, the baselayer 110 comprises rectangular ridges 310A-310B. Successive rectangularridges 310A-310B are separated from each other by a pitch 133. The pairof successive rectangular ridges 310A-310B again form between them arectangular groove 320. The rectangular groove 320 has a rectangulargroove width 330. The rectangular ridges 310A-310B each has a respectiveridge width 140A-140B. The respective ridge widths 140A-140B are eachapproximately equal to one third of the groove width 330. Accordingly, atop surface area 335 is approximately equal to one third of a floorsurface area 340. Therefore the top surface area 335 is approximatelyequal to one fourth of the top surface area of non-texturized prior arthaving a similar shape, and therefore the reflectance of the texturized,functionalized high-performance optical absorber 100 should be reducedto approximately 25% of non-texturized, functionalized prior art havinga similar shape.

As an example, the optical absorber 100A comprising therectangularly-texturized base layer 110 and further comprising thefunctionalized surface layer 120 as illustrated in FIG. 3A with 3:1floor-to-top surface area ratio has a reflectance value that isapproximately ¼ that of non-textured functionalized CNT and >20× lessthan non-functionalized CNT sheet. The combined effects offunctionalization and texturing together produce optical absorbers 100Awith substantially lower optical reflectance properties. Texturizationand plasma treatment are substantially independent factors that multiplytogether mathematically.

FIG. 3B depicts another optical absorber 100B comprising a base layer110 having a texturization geometry that comprises triangular ridges350A-350D, the optical absorber 100B further comprising thefunctionalized surface layer 120.

FIG. 3C depicts another optical absorber 100C comprising a base layer110 having a texturization geometry that comprises pyramidal ridges360A-360Z, the optical absorber 100B further comprising thefunctionalized surface layer 120.

FIG. 3D depicts another optical absorber 100D comprising a base layer110 having a texturization geometry that comprises truncated pyramidalridges 380A-3800, the optical absorber 100B further comprising thefunctionalized surface layer 120.

FIG. 4 is a graph 400 of modeling data depicting superior absorbanceperformance relative to the prior art of a high-performance opticalabsorber comprising a non-texturized base layer, the base layercomprising one or more of a polymer film and a polymer coating, theoptical absorber further comprising a surface layer located above andimmediately adjacent to the base layer, the surface layer comprising aplasma-functionalized, non-woven CNT sheet.

FIG. 4 depicts a plot of Fresnel reflectance (as a percentage) 410plotted against a medium refractive index ratio m 420, wherem=n₁/n_(air), where n₁ is the refractive index of the medium and n_(air)is the refractive index of air. As shown in FIG. 4 , the Fresnelreflection is reduced by the inventive high-performance optical absorberfrom approximately 18% at unoxidized data point 430 to approximately7.7% for visible light at diffuse incidence (shown as item 434 in thefigure) at diffuse incidence data point 440, representing a reduction inreflectance by a factor of approximately 2.4. As also shown in FIG. 4 ,the Fresnel reflection is reduced by the inventive high-performanceoptical absorber from approximately 18% at the unoxidized data point 430to approximately 2.7% for visible light at normal incidence (shown asitem 444 in the figure) at normal incidence data point 450, representinga reduction in reflectance by a factor of approximately 6.4. Thesereflection reductions factors should be approximately valid throughoutthe visible spectrum up through infrared wavelengths of approximately1,600 nanometers (nm).

Macro-texturing of the base layer as illustrated in FIG. 1 and FIGS.3A-3D further reduces the reflectance properties of the sheet material.Texturization is more effective when combined with surfacefunctionalization treatment as outlined in this application. Ahigh-performance optical absorber comprising a texturized base layer,the base layer comprising one or more of a polymer film and a polymercoating, the optical absorber further comprising a surface layer locatedabove and immediately adjacent to the base layer, the surface layercomprising a plasma-functionalized, non-woven CNT sheet.

The high-performance optical absorber comprising a non-texturized baselayer, the base layer comprising one or more of a polymer film and apolymer coating, the optical absorber further comprising a surface layerlocated above and immediately adjacent to the base layer, the surfacelayer comprising a plasma-functionalized, non-woven CNT sheet, exhibitsa hemispherical reflectance less than approximately 0.5-1.5% over thevisible spectral range versus 2-8% for prior art non-functionalizedmaterial. When texturization is used according to embodiments of theinvention in combination with functionalization, reflectance levels canbe expected to be further reduced, below half of the reflectanceachieved with functionalization but without texturization.

FIG. 5 is a flow chart of a method 500 using capillary force lamination(CFL) for manufacturing a high-performance optical absorber.

The order of the steps in the method 500 is not constrained to thatshown in FIG. 5 or described in the following discussion. Several of thesteps could occur in a different order without affecting the finalresult.

In step 510, a base layer of the high-performance optical absorber istexturized, the base layer comprising one or more of a polymer film anda polymer coating. Block 510 then transfers control to block 520.

In step 520, a surface layer of the high-performance optical absorber isjoined to the base layer, the surface layer comprising a non-wovencarbon nanotube (CNT) sheet. Block 520 then transfers control to block530.

In step 530, the joined surface layer and base layer are wetted with asolvent. Block 530 then transfers control to block 540.

In step 540, the resulting joined surface layer and base layer aredried. Block 540 then transfers control to block 550.

In step 550, the resulting base layer is treated with plasma, creatingthe high-performance optical absorber. The plasma functionalization step550 may be performed one or more of prior to and subsequent to thewetting step 530. Block 550 then terminates the process.

FIG. 6 is a flow chart of a method 600 using capillary force lamination(CFL) for manufacturing a high-performance optical absorber.

The order of the steps in the method 600 is not constrained to thatshown in FIG. 6 or described in the following discussion. Several of thesteps could occur in a different order without affecting the finalresult.

In step 610, a base layer of the high-performance optical absorber istexturized, the base layer comprising one or more of a polymer film anda polymer coating. Block 610 then transfers control to block 620.

In step 620, a surface layer of the high-performance optical absorber isjoined to the base layer, the surface layer comprising a non-wovencarbon nanotube (CNT) sheet. Block 620 then transfers control to block630.

In step 630, the joined surface layer and base layer are wetted with asolvent. Block 630 then transfers control to block 640.

In step 640, surface tension forces of the solvent are allowed to drawthe non-woven CNT sheet into the base layer, thereby texturizing thesurface layer. Block 640 then transfers control to block 650.

In step 650, the resulting joined surface layer and base layer aredried. Block 650 then transfers control to block 660.

In step 660, the resulting base layer is treated with plasma, creatingthe high-performance optical absorber. The plasma functionalization step550 may be performed one or more of prior to and subsequent to thewetting step 530. Block 550 then terminates the process.

The plasma functionalization step 660 may be performed one or more ofprior to and subsequent to the wetting step 630. Step 660 thenterminates the process.

An advantage of embodiments of the invention is that they provide apractical method for producing higher performance optical absorber filmsand optical absorber coatings for use in aerospace instruments as wellas for solar energy conversion applications.

An additional advantage of embodiments of the invention is that combinedsurface functionalization and texturization treatment of a non-woven CNTsheet creates a dielectric/conductor structure that can have amultiplicative effect in enhancing light absorbance properties of theresulting material. Design of the structure may be tailored depending ondetails of the texturization. Reduction in Fresnel reflection resultingfrom the change in refractive index with plasma treatment of thenon-woven CNT sheet is substantial.

A further advantage of embodiments of the invention is that embodimentsof the invention are physically robust and strong, unlike fragile priorart vertically aligned CNT array (VACNT) materials. A further advantageof embodiments of the invention is they avoid contamination issuespresent in space applications of the prior art VACNT materials includingpaint coatings, which do one or more of offgas, flake, and generatelight-scattering particulates in telescope applications. A yetadditional advantage of embodiments of the invention in that they areusable to coat one or more of internal barrel surfaces and smallradius-edged vanes of one or more of telescopes and optical instruments.A further advantage of embodiments of the invention is that relative tothe prior art, they can be applied without damaging a surface's opticalabsorbance properties. A still other advantage of embodiments of theinvention is that relative to the prior art, they are suitable for largearea coating applications such as applications involving areas ofapproximately several square meters as well as for applicationsinvolving smaller areas. Another advantage of embodiments of theinvention is that relative to the prior art, embodiments of theinvention employ significantly fewer vanes and/or baffles in opticalinstrument designs while achieving higher stray light reduction levels.Accordingly, embodiments of the invention avoid attendant prior artdisadvantages of one or more of greater complexity, higher weight andhigher costs.

A further advantage of embodiments of the invention is that they providelow, omni-directional, Lambertian reflectance that producessubstantially uniform reflectance at all angles. According toembodiments of the invention, a refractive index n of the functionalized(and therefore partially oxidized) surface sub-layer is betweenapproximately 1.2 and approximately 1.6, compared to a refractive indexfor a non-functionalized, non-woven CNT sheet of approximately 2.5.

A further advantage of embodiments of the invention is that apolarization-insensitive absorber is provided. A still additionaladvantage of embodiments of the invention is that a broadband absorberis provided over a large range of wavelengths from the near-ultraviolet(wavelengths between approximately 250 nm and approximately 400 nm) intothe infrared.

Further advantages of embodiments of the invention are that theinvention provides robust and easy fabrication not requiring carefulcalibration of film thickness. A still additional advantage ofembodiments of the invention is the absence of a requirement for avacuum chamber for fabrication of the absorber's film or coating.

A yet further advantage of embodiments of the invention is theirrelatively high stability, that is, high resistance to changes inreflectivity over time and with exposure to space vacuum. Anotheradvantage of embodiments of the invention is their substantial stabilityto ultraviolet radiation down to the range of 250-275 nm wavelengths.

As shown in FIG. 4 , a further advantage of embodiments of the inventionis that relative to the prior art, the invention provides reduced CNTreflectance. The prior art includes one or more of non-woven CNT sheetsand buckypapers as manufactured by Nanocomp Technologies, Inc.(www.miralon.com) of Merrimack, New Hampshire, and carbon-loaded blackpaints such as one or more of Aeroglaze Z306 and Aeroglaze Z307polyurethane coatings, manufactured by Lord Corporation of Cary, NorthCarolina (www.lord.com). Modeling results conservatively indicate thatreflectance of the non-woven CNT sheet produced according to embodimentsof the invention may be reduced by a factor of more than twenty times.

A yet other advantage of embodiments of the invention is that thecapillary force lamination method can accommodate very large sheets, forexample, sheets having approximate dimensions of three feet by threefeet and even larger sheets.

Another advantage of embodiments of the invention is that enhancedabsorbance of texturized surfaces virtually eliminates secondary andtertiary ray reflection from functionalized groove walls, permittingonly reflection from the groove floor of light rays that are nearlynormal to the surface.

While the above representative embodiments have been described withcertain components in exemplary configurations, it will be understood byone of ordinary skill in the art that other representative embodimentscan be implemented using different configurations and/or differentcomponents. For example, it will be understood by one of ordinary skillin the art that the order of certain steps and certain components can bealtered without substantially impairing the functioning of theinvention. It will be further understood by those of skill in the artthat the number of variations of embodiments of the invention arevirtually limitless. For example, other horizontally-oriented surfacescoated with fibril particles can be used. For example, a texturizationgeometry could be used in which the ridges vary in one or more of pitchand geometry. For example, a texturization geometry could be used thatemploy geometries not comprising ridges. For example, a texturizationgeometry could combine into a single geometry one or more ofsubstantially rectangular ridges, substantially triangular ridges,substantially pyramidal ridges, and truncated, substantially pyramidalridges. For example, the texturization geometry could combine into asingle geometry a varying pitch, in which for example one ridge had acertain pitch of approximately and the adjacent ridge had a pitch ofapproximately half of that value.

The representative embodiments and disclosed subject matter, which havebeen described in detail herein, have been presented by way of exampleand illustration and not by way of limitation. It will be understood bythose skilled in the art that various changes may be made in the formand details of the described embodiments resulting in equivalentembodiments that remain within the scope of the invention. It isintended, therefore, that the subject matter in the above descriptionshall be interpreted as illustrative and shall not be interpreted in alimiting sense.

We claim:
 1. A method using capillary force lamination (CFL) formanufacturing a high-performance optical absorber, comprising:texturizing a base layer of the high-performance optical absorber, thebase layer comprising one or more of a polymer film and a polymercoating; joining a surface layer of the high-performance opticalabsorber to the base layer, the surface layer comprising a non-wovencarbon nanotube (CNT) sheet; wetting the joined surface layer and baselayer with a solvent; allowing surface tension forces of the solvent todraw the non-woven CNT sheet into the base layer, thereby texturizingthe surface layer; drying the joined surface layer and base layer; andtreating the resulting base layer with plasma, creating thehigh-performance optical absorber.
 2. The method of claim 1, furthercomprising a step of plasma-treating the surface layer.
 3. The method ofclaim 1, wherein the treating step further comprises treating theresulting base layer using oxygen plasma.
 4. The method of claim 1,wherein the step of texturizing the base layer further comprisescreating one or more of substantially rectangular ridges, substantiallytriangular ridges, substantially pyramidal ridges, and truncated,substantially pyramidal ridges.
 5. The method of claim 4, wherein thestep of texturizing the base layer further comprises creating a baselayer texturization having a pitch that is greater than or equal to10×λ, where λ is the wavelength of incident light on thehigh-performance optical absorber.
 6. The method of claim 1, wherein thejoining step further comprises laying the surface layer on the baselayer.
 7. The method of claim 1, wherein the surface layer comprisesmulti-walled CNTs (MWCNTs).
 8. The method of claim 1, wherein the stepof texturizing the base layer further comprises creating a base layerthat has a height above the surface layer greater than or equal to 10×λ,where λ is the wavelength of incident light on the high-performanceoptical absorber.
 9. The method of claim 1, wherein the texturizing stepfurther comprises one or more of embossing, engraving, andthree-dimensional printing.
 10. The method of claim 1, wherein the CNTsheet comprises horizontal, randomly-oriented CNT.
 11. The method ofclaim 1, wherein the step of texturizing the base layer furthercomprises creating substantially rectangular ridges.
 12. The method ofclaim 11, wherein each successive pair of the rectangular ridges formbetween them a rectangular groove.
 13. The method of claim 12, whereinthe rectangular grooves create respective floors.
 14. The method ofclaim 1, wherein the CNT sheet comprises a plasma-functionalized CNTsheet.
 15. The method of claim 14, wherein the CNT sheet has an arealdensity between approximately 10 grams per square meter (g/m²) andapproximately 30 g/m².
 16. The method of claim 14, wherein the surfacelayer comprises a non-functionalized surface sub-layer.
 17. The methodof claim 16, wherein the surface layer further comprises afunctionalized surface sub-layer below the non-functionalized surfacesub-layer, wherein an index of refraction of the non-functionalizedsurface sub-layer equals approximately 2.5.
 18. The method of claim 17,wherein an index of refraction of the functionalized surface sub-layeris between approximately 1.2 and approximately 1.6.
 19. The method ofclaim 1, wherein the CNT sheet has a porosity between approximately 40%and approximately 90%.
 20. The method of claim 1, wherein the CNT sheethas a porosity between approximately 65% and approximately 75%.